Apparatus for folding a sheet of material into a support structure

Abstract

Apparatus and methods for forming three dimensional structures from a sheet of material of a desired medium are described. Examples described include an apparatus for folding a sheet of material to create a folded structure, the apparatus having a first and second array of creasing elements, and at least one actuator for causing relative movement of the first and second array of creasing elements from a first position to a second position.

What is claimed is: 
     
       1. An apparatus for folding a sheet of material to create a folded structure, comprising a first array of creasing elements and a second array of creasing elements, each of the creasing elements having a leading edge adapted to engage the sheet of material, at least one actuator for causing relative movement of the first and second arrays of creasing elements from a first position in which the first and second plurality of creasing elements are spaced apart to a second position in which the first and second array of creasing elements are at least partially interdigitated and for moving the creasing elements of the first array closer together and the creasing elements of the second array closer together during relative movement of the first and second arrays of creasing elements to the second position whereby the sheet of material can be placed between the first and second arrays of creasing elements and folded by the leading edges of the creasing elements during the relative movement of the first and second arrays creasing elements to the second position and the movement of the creasing elements of the first array closer together and the creasing elements of the second array closer together accommodates contraction of the sheet of material as it is folded by the first and second arrays of creasing elements,
 wherein the creasing elements of the first array are disposed in rows and columns when viewed in plan and the creasing elements of the second array are disposed in rows and columns when viewed in plan, and adjacent creasing elements in each column of the first array are interconnected by a first column scissor assembly and adjacent creasing elements in each column of the second array are interconnected by a second column scissor assembly, and adjacent creasing elements in each row of the first array are interconnected by a first row scissor assembly and adjacent creasing elements in each row of the second array are interconnected by a second row scissor assembly. 
 
     
     
       2. The apparatus according to  claim 1 , wherein the at least one actuator includes at least one first actuator for causing relative movement of the first and second arrays of creasing elements from the first position to the second position and at least one second actuator for moving the creasing elements of the first array closer together and the creasing elements of the second array closer together during relative movement of the first and second arrays of creasing elements to the second position. 
     
     
       3. The apparatus of  claim 2 , wherein the at least one actuator includes a third actuator for causing movement of one of the first or second arrays relative to the other one of the first or second arrays such that columns of creasing elements of one of the first or second arrays are not aligned with columns of creasing elements of the other one of the first or second arrays. 
     
     
       4. The apparatus according to  claim 1 , wherein the number of columns in the first array of creasing elements is one less than the number of columns in the second array of creasing elements. 
     
     
       5. The apparatus according to  claim 4 , wherein the number of rows in the first array of creasing elements is equal to the number of rows in the second array of creasing elements. 
     
     
       6. The apparatus according to  claim 1 , wherein each of the rows of creasing elements in the first array is alignable in a plane with the respective row of creasing elements in the second array. 
     
     
       7. The apparatus according to  claim 6 , wherein the first array of creasing elements are moveable transversely relative to the second array of creasing elements so that the rows of creasing elements in the first array are not aligned in a plane with the rows of creasing elements in the second array. 
     
     
       8. The apparatus according to  claim 7 , further comprising at least one additional actuator for moving the first array of creasing elements relative to the second array of creasing elements so that the rows of creasing elements in the first array are not aligned in a plane with the rows of creasing elements in the second array when the first and second arrays of creasing elements are in the first position. 
     
     
       9. The apparatus of according to  claim 1 , wherein the columns of creasing elements in the first array are offset from the columns of creasing elements in the second array when viewed in plan so that columns of creasing elements in the first array are interdigitated with the columns of creasing elements in the second array when the first and second arrays of creasing elements are in the second position. 
     
     
       10. The apparatus according to  claim 9 , wherein the columns of creasing elements in the first array are centered between the columns of creasing elements in the second array when viewed in plan. 
     
     
       11. The apparatus according to  claim 1 , wherein the leading edges of the creasing elements of the first array are coplanar with each other when the first and second arrays of creasing elements are in the first position. 
     
     
       12. The apparatus according to  claim 11 , wherein the leading edges of the creasing elements of the second array are coplanar with each other when the first and second arrays of creasing elements are in the first position. 
     
     
       13. The apparatus according to  claim 12 , wherein the leading edge of the creasing elements of the second array are coplanar with each other and the leading edge of the creasing elements of the first array are coplanar with each other when the first and second arrays of creasing elements are in the first position.